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The Space Station Environmental Control and Life Support System (ECLSS) test program at the Marshall Space Flight Center (MSFC) is addressed. The immediate goals and current activities of the test program are discussed. Also described are the Core Module Integration Facility (CMIF) and the initial ECLSS test configuration. Future plans for the ECLSS test program and the CMIF are summarized.
NASA Lewis Research Center and its prime contractor are respnsible for developing the electrical power system on the Space Station. The power system will be controlled by a network of distributed processors. Control software will be verified, validated, and tested in hardware and software test beds. Current plans for the software test bed involve using real time and nonreal time simulations of the power system. This paper will discuss the general simulation objectives and configurations, control architecture, interfaces between simulator and controls, types of tests, and facility configurations.
The Systems Special Investigation Group (SIG) has undertaken investigations in the four major engineering disciplines represented in the Long Duration Exposure Facility (LDEF) hardware: electrical, mechanical, thermal, and optical systems. Testing was planned for the highest possible level of assembly, and top level system tests for nearly all systems were performed at this time. To date, testing was performed on a mix of LDEF and individual experimenter systems. No electrical or mechanical system level failures attributed to the spaceflight environment have yet been detected. Some low cost electrical components were used successfully, although relays were a continuing problem. Mechanical galling was observed unexpectedly, but no evidence of cold welding was identified yet. A working index of observed systems anomalies was created and will be used to support the tracking and resolution of these effects. The LDEF hardware currently available to the Systems SIG includes most of the LDEF systems hardware, and some significant experimenter hardware as well. A series of work packages was developed for each of several subsystem types where further testing is of critical interest. The System SIG is distributing a regular newsletter to the greater LDEF community in order to maintain coherence in an investigation which is widely scattered both in subject matter and in geography. Circulation of this informal document has quadrupled in its first year.
The Systems Special Investigation Group (SIG) has undertaken investigations in the four major engineering disciplines represented by LDEF hardware: electrical, mechanical, thermal, and optical systems. Testing was planned for the highest possible level of assembly, and top level system tests for nearly all systems were performed at this time. Testing to date was performed on a mix of LDEF and individual experimenter systems. No electrical or mechanical system level failures attributed to the spaceflight environment were detected by the Systems SIG. Some low cost electrical components were used successfully, although relays were a continuing problem. Extensive mechanical galling was observed, but no evidence of coldwelding was identified. A working index of observed systems anomalies was created and will be used to support the tracking and resolution of these effects. LDEF hardware currently available to the Systems SIG includes most of the LDEF facility systems hardware, and some significant experimenter hardware as well. A series of work packages was developed for each of several subsystem types where further testing is of critical interest. The Systems SIG is distributing a regular newsletter to the greater LDEF community in order to maintain coherence in an investigation which is widely scattered both in subject matter and in geography. Circulation of this informal document has quadrupled in its first year.
An Integrated Product Team (IPT) was formed to develop a detailed optical test methodology for testing of the Next Generation Space Telescope (NGST) mirrors and the optical system on the ground. Optical testing is a significant cost driver therefore the testing has to be planned in detailed fashion early. This paper will discuss the preliminary metrology test plan at the mirror component and telescope system level. Instrumentation, facilities and schedule will also be addressed.
Multipoint Lean-Direct-Injection (LDI) is a combustor concept in which a large number of fuel injectors and fuel-air mixers are used to quickly and uniformly mix the fuel and air so that ultralow levels of NO, are produced. Each fuel injector has an air swirler associated with it for fuel-air mixing and to establish a small recirculation and burning zone. A concept in which there are 36 fuel injectors in the space of a conventional single fuel injector has been tested in a flame tube. A greater than 80 percent reduction in NO, at high power conditions (400 psia, 1000 "Finlet) was achieved. Alternate concepts with 9,25,36 or 49 fuel injectors are being investigated in flame tube tests for their low NO, potential and with fuel staging to improve the turn-down ratio at low power conditions. A preliminary sector concept of a large engine design has been successfully tested at inlet conditions of 700 psia and 1100 O F . This concept had one half the number of fuel injectors per square inch as the flame tube configuration with 36 fuel injectors, and the NO, reduction was 65 percent of the ICAO standard. Future regional engine size sector tests are planned for the 2nd quarter of FY02 and large engine size sector tests for the 1st quarter of FY03.
A team at the NASA Johnson Space Center (JSC) is undergoing final preparations to test Surface Acoustic Wave (SAW) Radio Frequency Identification (RFID) technology to track assets aboard the International Space Station (ISS). Currently, almost 10,000 U.S. items onboard the ISS are tracked within a database maintained by both the JSC ground teams and crew onboard the ISS. This barcode-based inventory management system has successfully tracked the location of 97% of the items onboard, but its accuracy is dependant on the crew to report hardware movements, taking valuable time away from science and other activities. With the addition of future modules, the volume of inventory to be tracked is expected to increase significantly. The first test of RFID technology on ISS, which will be conducted by the Expedition 16 crew later this year, will evaluate the ability of RFID technology to track consumable items. These consumables, which include office supplies and clothing, are regularly supplied to ISS and can be tagged on the ground. Automation will eliminate line-of-sight auditing requirements, directly saving crew time. This first step in automating an inventory tracking system will pave the way for future uses of RFID for inventory tracking in space. Not only are there immediate benefits for ISS applications, it is a crucial step to ensure efficient logistics support for future vehicles and exploration missions where resupplies are not readily available. Following a successful initial test, the team plans to execute additional tests for new technology, expanded operations concepts, and increased automation.
Shelter structures on the moon, even in early phases of exploration, should incorporate lunar materials as much as possible. This Technical Memorandum details the design and construction of a prototype for a one-piece regolith bag unpressurized garage concept and a materials testing program to investigate six candidate fabrics to learn how they might perform in the lunar environment. The conceptualization was that a lightweight fabric form be launched from Earth and landed on the lunar surface to be robotically filled with raw lunar regolith. Regolith bag fabric candidates included: Vectran(TM), Nextel(TM), Gore PTFE Fabric(TM), Zylon(TM), Twaron(TM), and Nomex(TM). Tensile (including post radiation exposure), fold, abrasion, and hypervelocity impact testing were performed under ambient conditions, and also performed under cold and elevated temperatures. In some cases, Johnson Space Center lunar simulant (JSC-1) was used in conjunction with testing. A series of preliminary structures was constructed during final prototype design based on the principles of the classic masonry arch. The prototype was constructed of Kevlar(TM) and filled with vermiculite. The structure is free-standing, but has not yet been load tested. Future plans would be to construct higher fidelity prototypes and to conduct appropriate tests of the structure.
The Spacesuit Water Membrane Evaporator (SWME) is the baseline heat rejection technology selected for development for the Constellation lunar suit. The first SWME prototype, designed, built, and tested at Johnson Space Center in 1999 used a Teflon hydrophobic porous membrane sheet shaped into an annulus to provide cooling to the coolant loop through water evaporation to the vacuum of space. This present study describes the test methodology and planning and compares the test performance of three commercially available hollow fiber materials as alternatives to the sheet membrane prototype for SWME, in particular, a porous hydrophobic polypropylene, and two variants that employ ion exchange through non-porous hydrophilic modified Nafion. Contamination tests will be performed to probe for sensitivities of the candidate SWME elements to ordinary constituents that are expected to be found in the potable water provided by the vehicle, the target feedwater source. Some of the impurities in potable water are volatile, such as the organics, while others, such as the metals and inorganic ions are nonvolatile. The non-volatile constituents will concentrate in the SWME as evaporated water from the loop is replaced by the feedwater. At some point in the SWME mission lifecycle as the concentrations of the non-volatiles increase, the solubility limits of one or more of the constituents may be reached. The resulting presence of precipitate in the coolant water may begin to plug pores and tube channels and affect the SWME performance. Sensitivity to macroparticles, lunar dust simulant, and air bubbles will also be investigated.
The Space Suit Water Membrane Evaporator (SWME) is the baseline heat rejection technology selected for development for the Constellation lunar suit. The Hollow Fiber (HoFi) SWME is being considered for service in the Constellation Space Suit Element (CSSE) Portable Life Support Subsystem (PLSS) to provide cooling to the thermal loop through water evaporation to the vacuum of space. Previous work described the test methodology and planning to compare the test performance of three commercially available hollow fiber materials as alternatives to the sheet membrane prototype for SWME: 1) porous hydrophobic polypropylene, 2) porous hydrophobic polysulfone, and 3) ion exchange through nonporous hydrophilic modified Nafion. Contamination tests were performed to probe for sensitivities of the candidate SWME elements to organics and non-volative inorganics expected to be found in the target feedwater source, i.e., potable water provided by the vehicle. The resulting presence of precipitate in the coolant water could plug pores and tube channels and affect the SWME performance. From this prior work, a commercial porous hydrophobic hollow fiber was selected to satisfy both the sensitivity question and the need to provide 800 W of heat rejection. This paper describes the trade studies, the design methodology, and the hollow fiber test data used to design a full
Topics to be Covered in this presentation are: (1) Integration and Test (I&T) Planning (2) Integration and Test Flows (3) Overview of Typical Mission I&T (4) Supporting Elements (5) Lessons-Learned and Helpful Hints (6) I&T Mishaps and Failures (7) The Lighter Side of I&T and (8) Small-Group Activity. This presentation highlights a typical NASA "in-house" I&T program (1) For flight systems that are developed by NASA at a space flight center (like GSFC) (2) Requirements well-defined: qualification/acceptance, documentation, configuration management. (3) Factors: precedents, human flight, risk-aversion ("failure-phobia"), taxpayer dollars, jobs and (4) Some differences among NASA centers, but generally a resource-intensive process
Integrated testing (such as Multi-Element Integrated Test (MEIT)) is critical to reducing risks and minimizing problems encountered during assembly, activation, and on-orbit operation of large, complex manned spacecraft. Provides the best implementation of "Test Like You Fly:. Planning for integrated testing needs to begin at the earliest stages of Program definition. Program leadership needs to fully understand and buy in to what integrated testing is and why it needs to be performed. As Program evolves and design and schedules mature, continually look for suitable opportunities to perform testing where enough components are together in one place at one time. The benefits to be gained are well worth the costs.
For long-term human exploration of the Moon and Mars to be practical, affordable, and sustainable, future missions must be able to identify and utilize resources at the site of exploration. The ability to characterize, extract, processes, and separate products from local material, known as In-Situ Resource Utilization (ISRU), can provide significant reductions in launch mass, logistics, and development costs while reducing risk through increased mission flexibility and protection as well as increased mission capabilities in the areas of power and transportation. Making mission critical consumables like propellants, fuel cell reagents and life support gases, as well as in-situ crew/hardware protection and energy storage capabilities can significantly enhance robotic and human science and exploration missions, however other mission systems need to be designed to interface with and utilize these in-situ developed products and services from the start or the benefits will be minimized or eliminated. This requires a level of surface and transportation system development coordination not typically utilized during early technology and system development activities. An approach being utilized by the US National Aeronautics and Space Administration and the Canadian Space Agency has been to utilize joint analogue field demonstrations to focus technology development activities to demonstrate and integrate new and potentially game changing. mission critical capabilities that would enable an affordable and sustainable surface infrastructure for lunar and Mars robotic and human exploration. Two analogue field tests performed in November 2008 and February 2010 demonstrated first generation capabilities for lunar resource prospecting, exploration site preparation, and oxygen extraction from regolith while initiating integration with mobility, science, fuel cell power, and propulsion disciplines. A third analogue field test currently planned for June 2012 will continue and expand the fidelity and integration of these surface exploration and infrastructure capabilities while adding Mars exploration technologies, improving remote operations and control of hardware, and promoting the use of common software, interfaces, & standards for control and operation for surface exploration and science. The next field test will also attempt to include greater involvement by industry, academia, and other countries/space agencies. This paper will provide an overview of the development and demonstration approach utilized to date, the results of the previous two ISRU-focused field analogue tests in Hawaii, and the current objectives and plans for the 3rd international Hawaii analogue field test.
An assessment is given of the critical and enhancing technologies necessary to build the basic personal terminal (BPT), the supplier, and the Network Management Center (NMC). The experimentation plan for testing the Personal Access Satellite System (PASS) utilizing ACTS is detailed. The experiment plan gives a list of candidate experiments and describes the proposed experimental set-up. ACTS will be used in the Microwave Switch Matrix (MSM) mode. The Microwave Switch Matrix - Link Evaluation Terminal (MSM-LET) at the NASA Lewis Research Center will serve as the microwave front-end for the PASS supplier and the NMC. Link budgets are given for both the forward and return links between the supplier and the basic personal terminal. The equipment required for the experiments is identified.
Successful operation of life support systems for space exploration missions of the future will require unique sophisticated sensor systems for highly dependable operation, i.e., autonomous and fault tolerant. These sensor systems will require the use of multifunctional in situ sensors that are strategically located throughout the life support systems. These sensors will communicate through control loops that are hierarchically interconnected at several levels of the life support system. Development of the sensor system must be done synergistically with the integration and testing of the subsystems, and their process units, as they are assembled and tested. The plan for proceeding with the sensor systems development and the integration with the test bed assembly and operation is described in this paper.
This paper is a summary of Space Shuttle Main Engine (SSME) off-nominal testing that occurred during 2008 and 2009. During the last two years of planned SSME testing at Stennis Space Center, Pratt & Whitney Rocketdyne worked with their NASA MSFC customer to systematically identify, develop, assess, and implement challenging test objectives in order to expand the knowledge of one of the world s most reliable and highly tested large rocket engine. The objectives successfully investigated three main areas of interest expanding engine performance margins, demonstrating system operational capabilities, and establishing ground work for new rocket engine technology. The testing gave the Space Shuttle Program new options to safely fly out the flight manifest and provided Pratt & Whitney Rocketdyne and NASA new insight into the operational capabilities of the SSME, capabilities which can be used in assessing potential future applications of the RS-25 engine.
Development of NASA's Space Launch System (SLS) heavy lift rocket is shifting from the formulation phase into the implementation phase in 2014, a little more than three years after formal program approval. Current development is focused on delivering a vehicle capable of launching 70 metric tons (t) into low Earth orbit. This "Block 1" configuration will launch the Orion Multi-Purpose Crew Vehicle (MPCV) on its first autonomous flight beyond the Moon and back in December 2017, followed by its first crewed flight in 2021. SLS can evolve to a130-t lift capability and serve as a baseline for numerous robotic and human missions ranging from a Mars sample return to delivering the first astronauts to explore another planet. Benefits associated with its unprecedented mass and volume include reduced trip times and simplified payload design. Every SLS element achieved significant, tangible progress over the past year. Among the Program's many accomplishments are: manufacture of Core Stage test panels; testing of Solid Rocket Booster development hardware including thrust vector controls and avionics; planning for testing the RS-25 Core Stage engine; and more than 4,000 wind tunnel runs to refine vehicle configuration, trajectory, and guidance. The Program shipped its first flight hardware - the Multi-Purpose Crew Vehicle Stage Adapter (MSA) - to the United Launch Alliance for integration with the Delta IV heavy rocket that will launch an Orion test article in 2014 from NASA's Kennedy Space Center. Objectives of this Earth-orbit flight include validating the performance of Orion's heat shield and the MSA design, which will be manufactured again for SLS missions to deep space. The Program successfully completed Preliminary Design Review in 2013 and Key Decision Point C in early 2014. NASA has authorized the Program to move forward to Critical Design Review, scheduled for 2015 and a December 2017 first launch. The Program's success to date is due to prudent use of proven technology, infrastructure, and workforce from the Saturn and Space Shuttle programs, a streamlined management approach, and judicious use of new technologies. The result is a safe, affordable, sustainable, and evolutionary path to development of an unprecedented capability for future missions across the solar system. In an environment of economic challenges, the nationwide SLS team continues to meet ambitious budget and schedule targets. This paper will discuss SLS program and technical accomplishments over the past year and provide a look at the milestones and challenges ahead.
The initial phase of hydrocarbon-fueled ground tests supporting Flight 2 of the Hypersonic International Flight Research Experiment (HIFiRE) Program has been conducted in the NASA Langley Arc-Heated Scramjet Test Facility (AHSTF). The HIFiRE Program, an Air Force-lead international cooperative program includes eight different flight test experiments designed to target specific challenges of hypersonic flight. The second of the eight planned flight experiments is a hydrocarbon-fueled scramjet flight test intended to demonstrate dual-mode to scramjet-mode operation and verify the scramjet performance prediction and design tools. A performance goal is the achievement of a combusted fuel equivalence ratio greater than 0.7 while in scramjet mode. The ground test rig, designated the HIFiRE Direct Connect Rig (HDCR), is a full-scale, heat sink, direct-connect ground test article that duplicates both the flowpath lines and the instrumentation layout of the isolator and combustor portion of the flight test hardware. The primary objectives of the HDCR Phase I tests are to verify the operability of the HIFiRE isolator/combustor across the Mach 6.0-8.0 flight regime and to establish a fuel distribution schedule to ensure a successful mode transition prior to the HiFIRE payload Critical Design Review. Although the phase I test plans include testing over the Mach 6 to 8 flight simulation range, only Mach 6 testing will be reported in this paper. Experimental results presented here include flowpath surface pressure, temperature, and heat flux distributions that demonstrate the operation of the flowpath over a small range of test conditions around the nominal Mach 6 simulation, as well as a range of fuel equivalence ratios and fuel injection distributions. Both ethylene and a mixture of ethylene and methane (planned for flight) were tested. Maximum back pressure and flameholding limits, as well as a baseline fuel schedule, that covers the Mach 5.84-6.5 test space have been identified.